Relocate your fuel pump (under side cover)

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Written by John Cosentini

Friday, 11 June 2004

Reprinted by permission from Mr Tidy's tech tips

I don't remember who came up with this idea, but I think this is a VERY CLEAN relocation scheme for the fuel pump. It may have been Bill H I think. I can't take credit for all of this. Many Forum members have contributed. John Cosentini

The guy that came up with the idea woke up today, errrr... Spokeup today. RC (RCHAMER1) did the pictures and write up on the fuelpump modification. In RC's own words.." By the way, my installation is still working great with absolutely no problems. I have had it this way for over 15,000 miles now."RCHamer....

Remove Seat, Tank, Fuel cover and bracket and proceed with the rest.

The relay in the front (on my picture) is the control relay for the fuel pump.

Set up prior to moving relay to outside of bracket. .

Another "after relocation" shot.

After relay behind bracket is moved to the outside, (relay moved is on the left hand side)

The fuel pump retains the rubber mount and hooks onto the bracket after you move the inner relay to the outside rear bracket.

Everything is then hidden behind the side cover with nothing showing.

Picture shows where I picked off the electrical

The blue/black wire in the corner of the relay socket is the wire you attach to for the fuel pump. Right there where you are, real nice. I used the original connector to make replacement a snap

I used the bullet connectors with silicone jackets (like Yamaha uses for the tail light connectors) and attached them to the fuel pump connector that was up under the tank.

This makes for a real easy change out if you ever have to replace the pump, no more mods are ever necessary

It took about 6 1/2 feet of fuel line to do the way I routed it.

I Have never had that much fuel line on a motorcycle before, maybe I can go an extra 5 miles with that amount of fuel line!!!

Another 2 views of relocated fuel pump.

2nd View

Pix to right shows how I routed across the battery box.

shows some more routing

I included 4KRZNs_left Side.jpg shows the left side after the relocation

Very clean looking side now

The Lightning Shift Rod, The Stainless Steel Floorboard Extension and even Mr. Tidy's 4 way flasher switch on the side cover all looks good.

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DISCLAIMER:
This information and procedure is provided
as a courtesy and is for informational purposes only.
Neither the publishers nor the authorsaccept any responsibility for the accuracy, applicability, or
suitability of this procedure. You assume all risks associated
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SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY
CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.
Any type of modification or service work on your motorcycle should
alwaysbe performed by a professional mechanic.If performed incorrectly,
this procedure mayendanger the safety of you and otherson your motorcycle and possibly
invalidate your manufacturer’s warranty.

choke knobWritten by jbbaonefam, on 08-31-2012 10:52 Somewhere I saw somebody say they had attached the choke cable somewhere by the tank, so that it was closer to reach to pull the choke.....is there a way to hide it without ruining the function and not making a bracket for the side?

Keeps stallingWritten by inthewind0484, on 10-01-2011 11:45 i relocated my fuel pump under my seat instead of where you put it but now every time i get to about 60-70 mph it like stalls out like it aint getting no gas?! i was wondering if i need to put heat wrap around all the lines so the gas dont boil? or have any of you had this problem? thanks for input

Choke knob?Written by mikeleblanc, on 11-28-2010 21:21 What bracket did you use to mount the choke knob after you relo'd the pump? I have the pump relo kit on the way and will be doing it this week, but haven't worked out the choke yet.

relocation of fuel pumpWritten by Spike, on 03-27-2008 11:55 Hey I did the relocation of the fuel pump on my 2004 Roadstar. I cannot seem to get it started..I get fuel to the fuel pump but nothing to the carb...Please help.... Thank you Spike

fuel pump relocationWritten by ZZ, on 11-21-2007 00:00 Just so I have this straight, the stock location of the fuel pump on my Roadie is in between the jugs under that little chrome cover on the left side, right? have thought to myself. having not looked, that that cover really takes away the looks to the engine. I do have a hypercharger on the other side and thought a tornado would do much to add to the opem look of the jugs. That is where harley really shines becase they don't obstruct the beauty of the engine. Hope this is not too dumb of a question. ZZ

fuel pump relocationWritten by liteflyer50, on 10-19-2007 09:16 other than the new fuel line and tie-wraps were there any other parts and out of pocket costs that you had?